Nomex aramid paper honeycomb is a composite material with a porous structure, characterized by low density and high specific strength, making it highly promising for applications in various fields. Milling is an important method for manufacturing Nomex honeycomb components, and the machining strategy employed can significantly affect the surface quality of the workpiece and subsequent bonding effectiveness, which are critical for the automation and integration of advanced production systems. To optimize machining strategies, finite element machining simulation and experimental testing were conducted, comparing two strategies: high-speed milling with traditional chip-breaking cutters and ultrasonic-assisted vibration milling. Simulation and experimental results indicate that ultrasonic-assisted cutting can improve the machining surface quality, with smaller surface stress deformation and lower damage levels on the workpiece. Specifically, the length of machining burrs decreased by 14.06% with ultrasonic-assisted milling, while the quality of milling with chip-breaking cutters was relatively poorer, resulting in a 15.63% increase in burr length, thereby supporting more consistent and reliable performance in digitally controlled assembly processes..